A groundbreaking £6 million research initiative is underway in the Midlands to develop the world’s first lightweight automotive and aerospace components made entirely from recycled aluminium. The PIVOT project, led by Coventry’s Sarginsons Industries with partners including Aston Martin, has secured matched funding from the Advanced Propulsion Centre and Innovate UK to transform sustainable manufacturing.
AI-Driven Design for Lighter, Stronger Components
Computational intelligence firm Altair is collaborating with Sarginsons to develop AI-powered software that creates organic, optimized component designs. This innovative approach simulates mechanical properties to strategically place material, potentially increasing strength while reducing mass by up to 30%. The technology promises to accelerate development cycles while cutting costs for manufacturers across automotive, aerospace and renewable sectors.
Transforming Aluminium’s Carbon Footprint
Currently reliant on high-carbon primary aluminium, the project aims to slash emissions by 95% through advanced recycling techniques. Working with Brunel University and GESCRAP, researchers are developing methods to refine recycled aluminium’s grain structure, overcoming traditional quality limitations. The shift to secondary aluminium could prevent the UK’s annual export of 250,000 tonnes of scrap metal while creating domestic jobs.
Building a Circular Supply Chain
The initiative will establish a new UK-based recycling network for high-grade aluminium, moving away from finite primary sources. Compared to primary aluminium’s 12-tonne carbon footprint per tonne, 100% recycled material emits just 0.5 tonnes – making it crucial for net-zero targets. The technology could set new global standards for sustainable metal use beyond automotive applications.
Midlands at the Forefront of Green Manufacturing
Sarginsons has committed £3 million to expand facilities and workforce for the project. Technical Director Gavin Shipley called it “the best £3m invested in the automotive industry,” highlighting its potential to redefine sustainable manufacturing globally. The research builds on the company’s existing capabilities at its Technology Centre, where it develops components for premium manufacturers.
The PIVOT project represents a significant step toward decarbonizing transportation while maintaining performance standards, with implications that could extend across multiple manufacturing sectors worldwide. Commercial applications are expected to begin with electric vehicles before expanding to other industries.
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